US6402873B1 - Method of manufacturing laminated thermoplastic resin sheet and apparatus therefor - Google Patents

Method of manufacturing laminated thermoplastic resin sheet and apparatus therefor Download PDF

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Publication number
US6402873B1
US6402873B1 US09/167,715 US16771598A US6402873B1 US 6402873 B1 US6402873 B1 US 6402873B1 US 16771598 A US16771598 A US 16771598A US 6402873 B1 US6402873 B1 US 6402873B1
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United States
Prior art keywords
thermoplastic resin
roll
cooling
resin sheet
endless belt
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Expired - Lifetime
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US09/167,715
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English (en)
Inventor
Atsushi Fujii
Akira Funaki
Masahiro Kubo
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Idemitsu Kosan Co Ltd
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Idemitsu Petrochemical Co Ltd
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Assigned to IDEMITSU PETROCHEMICAL CO., LTD reassignment IDEMITSU PETROCHEMICAL CO., LTD ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FUJII, ATSUSHI, FUNAKI, AKIRA, KUBO, MASAHIRO
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Assigned to IDEMITSU KOSAN CO.,LTD. reassignment IDEMITSU KOSAN CO.,LTD. CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: IDEMITSU PETROCHEMICAL CO., LTD.
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/15—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
    • B32B37/153—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state at least one layer is extruded and immediately laminated while in semi-molten state
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/06—Angles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/08—Dimensions, e.g. volume
    • B32B2309/10—Dimensions, e.g. volume linear, e.g. length, distance, width
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/08—Dimensions, e.g. volume
    • B32B2309/10—Dimensions, e.g. volume linear, e.g. length, distance, width
    • B32B2309/105—Thickness
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/17—Surface bonding means and/or assemblymeans with work feeding or handling means
    • Y10T156/1702—For plural parts or plural areas of single part
    • Y10T156/1712—Indefinite or running length work
    • Y10T156/1741—Progressive continuous bonding press [e.g., roll couples]

Definitions

  • the present invention relates to a method of manufacturing a thermoplastic resin sheet having a laminated structure and an apparatus therefor, and an obtained sheet can be used for packaging food products, medical and pharmaceutical products and the like.
  • a laminated thermoplastic resin sheet obtained by laminating a function film which applies an easy slipping characteristic, an oxygen barrier characteristic and the like to a base material sheet made of a polypropylene or the like, is used in a field of food products and the like.
  • the easily slipping film includes a nonoriented polypropylene film and the like, and the oxygen barrier film includes an EVOH film and the like.
  • thermoplastic resin sheet is manufactured by a coextrusion method, a dry laminate method or the like.
  • the adhesive layer prevents a transparency. Further, it is hard to manufacture a multiple layer sheet made of resins having different melting characteristics with increasing transparency. Still further, since a rate of an edge portion of the sheet to be trimmed is relatively large, a cost loss is increased in the case that the function film is expensive such as the EVOH film.
  • an object of the present invention is to provide a method of manufacturing a laminated thermoplastic resin sheet having an improved transparency without generating a wrinkles and an apparatus therefor.
  • a method of manufacturing a laminated thermoplastic resin sheet which uses a manufacturing apparatus comprising a first cooling roll having a surface coated by an elastic material, a second roll, a metal endless belt wound between the first roll and the second roll and a third cooling roll, brought into contact with the first cooling roll through the metal endless belt, comprising the steps of arranging a guide roll for introducing a film near the first or third roll so as to introduce a thermoplastic resin sheet in a melting state between the first and third cooling rolls in such a manner as to be brought into contact with the metal endless belt supported by the first cooling roll and the third cooling roll substantially at the same time, introducing a thermoplastic resin film between the metal endless belt and the third cooling roll through the guide roll so as to laminate the sheet and the film, pressing and cooling the laminated thermoplastic resin sheet in a plane manner by the first and third rolls while elastically deforming the elastic material by a pressing force between the first and third rolls, and continuously pressing and cooling the laminated thermoplastic resin
  • the metal endless belt and the rolls are formed in a mirror surface having a surface roughness 0.5 S or less.
  • a stainless steel, a carbon steel, a titanium alloy and the like can be used for a material of the metal endless belt.
  • a thickness of the endless belt can be optionally selected, however, from the view point of the belt strength, e.g. 0.3 mm or more is preferable.
  • At least the first cooling roll and the second roll are situated at the inside of the endless belt, and the other tolls for adjusting a tension and for cooling in an auxiliary manner may be included.
  • a fluorine rubber, a silicone rubber, an EPDM, an NBR and the like can be used for the elastic material. Further, it is preferable to set a thickness of the elastic material to be 3 mm or more for obtaining an improved plane pressure by an elastic deformation.
  • thermoplastic resin sheet in the melting state corresponds to, for example, a thermoplastic resin sheet immediately after being extruded from a T die of an extruding machine.
  • the thermoplastic resin sheet becomes a base material sheet, and a material thereof can be optionally selected among a polyethylene, a polypropylene, a polystyrene, a nylon and the like.
  • the thermoplastic resin film corresponds to, for example, a formed film fed out from a film supply roll.
  • the thermoplastic resin film corresponds to a function film applying functions such as an easy slipping characteristic, an oxygen barrier characteristic and the like to the base material sheet.
  • functions such as an easy slipping characteristic, an oxygen barrier characteristic and the like to the base material sheet.
  • a non oriented polypropylene film or the like is employed, and in the case of the oxygen barrier film, an EVOH film is employed.
  • the thermoplastic film may have a multiple layer structure, for example, a two layer structure comprising EVOH layer/PP layer, and a three layer structure comprising PP layer/EVOH layer/PP layer.
  • thermoplastic resin film can be optionally selected,.however, 10 to 1000 ⁇ m is preferable. Cooling means may be provided in the first to third rolls.
  • thermoplastic resin sheet and film are relatively different from each other only in view of a thickness, any of them may be called as the sheet or the film.
  • the sheet and the film are pressed and laminated in a plane manner together with an elastic deformation of the elastic material, a bonding strength between the laminated sheets is improved, and a rate of shrinkage at a time of laminating can be controlled within a certain small range.
  • the film is brought into a little contact with the endless belt or the third roll, so that the thermoplastic resin film can be prevented from generating a wrinkle as much as possible.
  • a method of manufacturing a laminated thermoplastic resin sheet as recited in the first aspect wherein the guide roll for introducing the film is arranged at a position at which an angle formed by a line between both centers of the first and third rolls and a contact point of the thermoplastic resin film with the endless belt or the third roll is 45 degrees or less.
  • the angle is set to be 45 degrees or less in order to prevent wrinkling this as much as possible.
  • the angle is preferably 30 degrees or less.
  • the object to be contacted is set to the endless belt or the third roll for the reason of corresponding to the case that the thermoplastic resin film is laminated on one surface (a front surface) or another surface (a back surface) of the thermoplastic resin sheet.
  • a definition is made by the angle formed by a line between both centers of the first and third rolls and the contact point of the thermoplastic resin film with the endless belt or the third roll, however, a definition may be made by an introducing angle of the thermoplastic resin film to a nip portion (between the first and third cooling rolls) with respect to the line between both centers of the first and third rolls, and it is preferable as the angle is near 90 degrees.
  • thermoplastic resin sheet as stated in the first or second aspect, wherein a back tension 9.8 N/m to 294.0 N/m is applied to the thermoplastic resin film.
  • the back tension can be applied by adjusting a speed of a supply device for the thermoplastic resin film.
  • the back tension is less than 9.8 N/m, an effect of sufficiently preventing a generation of a wrinkle and an effect of improving a stability in manufacturing can not be obtained. Further, when it is more than 294.0 N/m, there is a risk that the thermoplastic resin film extends so that a width of the film is narrowed.
  • thermoplastic resin sheet as stated in any one of the first to third inventions, wherein the thermoplastic resin film is laminated on either the one surface or another surface of the molten thermoplastic resin sheet through the guide roll for introducing the film.
  • thermoplastic resin sheet structured to have at least three layers in which thermoplastic resin films are respectively laminated on an upper layer and a lower layer of the thermoplastic resin sheet as an intermediate layer.
  • an apparatus for manufacturing a laminated thermoplastic resin sheet comprising a first cooling roll having a surface coated by an elastic material, a second roll, a metal endless belt wound between the first roll and the second roll, a third cooling roll brought into contact with the first cooling roll through the metal endless belt, molten resin supplying means arranged so as to introduce a thermoplastic resin sheet in a melting state between the first and third cooling rolls in such a manner as to be brought into contact with the metal endless belt contact with the first cooling roll and the third cooling roll substantially at the same time, and a guide roll for introducing the film arranged near the first or third roll so as to introduce a thermoplastic resin film between the metal endless belt and the third cooling roll.
  • the present invention corresponds to an apparatus for realizing the first method discussed above.
  • an apparatus for manufacturing a laminated thermoplastic resin sheet as recited in the fifth aspect wherein the guide roll for introducing the film is arranged at a position at which an angle formed by a line between both centers of the first and third rolls and a contact point of the thermoplastic resin film with the endless belt or the third roll is 45 degrees or less.
  • the present invention corresponds to an apparatus for realizing the second method discussed above.
  • an apparatus for manufacturing a laminated thermoplastic resin sheet as recited in the fifth or sixth aspect wherein the guide roll for introducing the film is arranged in either one surface or another surface of the molten thermoplastic resin sheet.
  • the present invention corresponds to an apparatus for realizing the fourth method discussed above.
  • FIG. 1 is a schematic view of a manufacturing apparatus used in a method of manufacturing a laminated thermoplastic resin sheet in accordance with an embodiment of the present invention.
  • the manufacturing apparatus is constituted by a T die 12 of an extruding machine for supplying a thermoplastic resin sheet 11 , a metal endless belt 15 wound between a first cooling roll 13 and a second cooling roll 14 , a third cooling roll 16 brought into engagement with the first roll 13 through the metal endless belt 15 , and a film supply roll 23 for supplying a formed thermoplastic resin film 22 . Further, a fourth roll 21 for adjusting a tension and cooling in an auxiliary manner is provided within a path inside the endless belt 15 .
  • the first roll 13 is structured such that an elastic member 18 such as a fluorine rubber or the like is coated on an outer peripheral surface thereof.
  • the elastic material 18 is structured such that a hardness (on the basis of JIS K6301 A type) thereof is 95 degrees or less, and a thickness thereof is 3 mm or more.
  • the metal endless belt 15 is made of stainless steel or the like, and is provided with a mirror surface having a surface roughness 0.5 S or less.
  • At least one of the first and second rolls 13 and 14 is structured such that a rotating shaft 19 thereof is connected to rotation drive means (not shown).
  • the third roll 16 is a metal roll and is provided with a mirror surface having a surface roughness 0.5 S or less.
  • the third roll 16 is arranged at a position at which the metal endless belt 15 is held in a part of a peripheral surface thereof. That is, the metal endless belt 15 moves in a zigzag direction so as to wind around a part of the outer peripheral surface of the third roll 16 .
  • first guide roll 24 and second guide roll 25 for introducing the thermoplastic resin film are arranged between the film supply roll 23 and a nip portion 26 (between the first cooling roll 13 and the third cooling roll 16 ) so as to introduce the thermoplastic resin film 22 between the endless metal belt 15 and the third cooling roll 16 .
  • first guide roll 24 is arranged between the extruder 12 and the first cooling roll 13 and a second first guide roll 24 (shown in phantom lines) is arranged between the extruder 12 and the third cooling roll 16 .
  • the first guide roll 24 is arranged near the first roll 13 .
  • a distance between the first guide roll 24 and the nip portion 26 is preferably set to be 500 mm or less so as to prevent a wrinkle from generating.
  • the guide roll 24 has a slight curve, and is an expander roll capable of removing a wrinkle.
  • the first guide roll 24 is arranged at a position at which an angle a formed by a line 27 between both centers of the first and third rolls 13 and 16 and a contact point of the thermoplastic resin film 22 with the endless belt 15 is 45 degrees or less.
  • thermoplastic resin film 22 a back tension 9.8 N/m to 294.0 N/m is applied to the thermoplastic resin film 22 by controlling a rotation of the film supply roll 23 .
  • the second guide roll 25 is provided at a suitable position in the side of the film supply roll 23 .
  • Temperature adjusting means (not shown) of a water cooling type or the like capable of adjusting a temperature of the surface is provided in each of the rolls 13 , 14 , 16 and 21 .
  • thermoplastic resin film 22 extruded out from the film supply roll 23 is introduced to the nip portion 26 through the first guide roll 24 , so that the sheet 11 and the film 22 are laminated and cooled at the same time.
  • the elastic material 18 elastically deforms in such a manner as to be compressed by a pressing force between the first and third rolls 13 and 16 , and the sheet 11 and the film 22 is in a plane pressure contact state by both roll 13 and 16 at a portion having an angle ⁇ 1 from a center of both rolls 13 and 16 at which the elastic member 18 is elastically deformed.
  • the laminated thermoplastic resin sheet 31 is pressed to the third roll 16 by the endless belt 15 and cooled.
  • the laminated thermoplastic resin sheet 31 pressed to the roll 16 by the endless belt 15 is held to the roll 16 at a holding angle ⁇ 2 from a center of the roll 16 , and the laminated thermoplastic resin sheet 31 is pressed in a plane manner at the portion having the holding angle ⁇ 2 by the endless belt 15 and the third roll 16 .
  • the laminated thermoplastic resin sheet 31 is removed from the endless belt 15 , and taken up to a take-up roll (not shown) partially around a third guide roll 17 .
  • the structure may be made such that the third guide roll 17 is provided near the second roll 14 , the laminated thermoplastic resin sheet 31 closely attached to the endless belt 15 is moved to the second roll 14 in accordance with a rotation of the endless belt 15 , and a further cooling is performed by the second roll 14 .
  • thermoplastic resin film 22 is introduced to the nip portion 26 through the first guide roll 24 at a time of laminating the sheet 11 and the film 22 , a contact portion of the thermoplastic resin film 22 with the endless belt 15 is reduced, and a generation of a wrinkle in the thermoplastic resin film 22 can be prevented, so that the laminated thermoplastic resin sheet 31 without a wrinkle can be obtained.
  • the structure is made such that the thermoplastic resin film 22 is laminated on one surface of the thermoplastic resin sheet 11 .
  • the structure is made such that the film supply roll 23 for supplying another thermoplastic resin film 22 and first and second guide rolls 24 and 25 for introducing the thermoplastic resin film 22 are further provided on the back of the thermoplastic resin sheet 11 , so that the thermoplastic resin film 22 can be laminated on both surfaces of the thermoplastic resin sheet 11 .
  • the first guide roll 24 for introducing the other thermoplastic resin film 22 is arranged at a position at which the angle a formed by the line 27 between both centers of the first and third rolls 13 and 16 and the contact point of the thermoplastic resin film 22 with the third roll 16 is 45 degrees or less.
  • a laminated thermoplastic resin sheet 31 is manufactured by setting particular conditions of a manufacturing apparatus and a manufacturing method as follows:
  • Elastic member of first roll . . . silicone rubber, thickness: 10 mm, hardness: 40 degrees;
  • Thermoplastic resin sheet . . . polypropylene sheet [IDEMITSU POLYPRO F-205S produced by IDEMITSU Petrochemical Co., Ltd];
  • Thermoplastic resin film . . . three layer structure of polypropylene (30 ⁇ m)/EVOH (30 ⁇ m)/polypropylene (30 ⁇ m);
  • Laminated thermoplastic resin sheet . . . thickness; 0.3 mm, width: 1200 m.
  • thermoplastic resin film 22 is changed as follows:
  • thermoplastic resin film 22 Only the angle ⁇ and the tension of the thermoplastic resin film 22 are changed as follows.
  • thermoplastic resin film 22 Only the angle ⁇ and the tension of the thermoplastic resin film 22 are changed as follows.
  • the first guide roll 24 for introducing the film 22 is not provided in the apparatus in accordance with example 1, and the angle ⁇ is 60 degrees.
  • thermoplastic resin film 22 In the case of a comparative example 2, in example 1, only the tension of the thermoplastic resin film 22 is changed to 400.0 N/m.
  • the laminated thermoplastic resin sheet 31 is the same as in example 1 and is manufactured in accordance with a coextrusion method.
  • a preferred adhesive is Admer QB550 (trade name).
  • the haze and gloss are measured in accordance with JIS K 7105.
  • thermoplastic resin film 22 is introduced to the nip portion 26 through the first guide roll 24 for introducing the film 22 at a time laminating together the thermoplastic resin sheet 11 and the thermoplastic resin film 22 , the laminated thermoplastic resin sheet 31 having a good haze and gloss can be obtained.
  • thermoplastic resin film 22 since the first guide roll 24 for introducing the film 22 is not provided, a contact length of the thermoplastic resin film 22 with the endless belt 15 is too long so that a wrinkle is generated in the laminated thermoplastic resin sheet 31 .
  • the back tension is too large, so that the thermoplastic resin film 22 is extended so as to make it hard to control a width thereof.
  • the obtained laminated thermoplastic resin sheet 31 has a high haze and is deteriorated in transparency.
  • the laminated thermoplastic resin sheet 31 having an improved transparency can be manufactured without generating a wrinkle.

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  • Laminated Bodies (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)
US09/167,715 1997-10-08 1998-10-07 Method of manufacturing laminated thermoplastic resin sheet and apparatus therefor Expired - Lifetime US6402873B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP9-275801 1997-10-08
JP27580197A JP3683688B2 (ja) 1997-10-08 1997-10-08 積層熱可塑性樹脂シートの製造方法及びその製造装置

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US6402873B1 true US6402873B1 (en) 2002-06-11

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US (1) US6402873B1 (fr)
EP (1) EP0908295B1 (fr)
JP (1) JP3683688B2 (fr)
AT (1) ATE230347T1 (fr)
DE (1) DE69810414T2 (fr)
ES (1) ES2189063T3 (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050034806A1 (en) * 2003-03-05 2005-02-17 Tilia International, Inc. Method for manufacturing liquid-trapping bag for use in vacuum packaging
US20070063374A1 (en) * 2004-11-08 2007-03-22 Nicholas Barakat System and method for making polyethylene terephthalate sheets and objects
US20100282412A1 (en) * 2009-05-09 2010-11-11 Dohe Dieter Method of making a protective film
US20120181715A1 (en) * 2004-11-08 2012-07-19 Nicholas Barakat Advanced control system and method for making polyethylene terephthalate sheets and objects

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7078075B1 (en) 1995-02-23 2006-07-18 H.B. Fuller Licensing & Financing Inc. Method for producing a continuous thermoplastic coating and articles constructed therefrom
DE19753266B4 (de) 1997-12-01 2010-10-07 H.B. Fuller Licensing & Financing, Inc., St. Paul Verfahren zum Verbinden luftundurchlässiger Materialien
US20100030180A1 (en) * 2006-10-18 2010-02-04 Tekni-Plex Europe, Naamloze Vennootschap Method for manufacturing a multi-layered film and film manufactured by said method
KR100821322B1 (ko) * 2007-02-21 2008-04-11 김소자 합성수지시트를 제조하는 장치 및 이에 사용되는 롤러 장치
CN106738760A (zh) * 2016-12-30 2017-05-31 桂林橡胶设计院有限公司 多层胶片柔性压合成型装置及其成型方法

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US2607712A (en) * 1952-01-28 1952-08-19 Frank W Egan & Company Extrusion coating machine
US2690206A (en) * 1953-03-23 1954-09-28 Marathon Corp Extrusion coating machine
US3017302A (en) * 1958-01-31 1962-01-16 Milprint Inc Art of packaging commodities
US3470055A (en) * 1965-01-21 1969-09-30 Nat Distillers Chem Corp Extrusion coating method
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Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050034806A1 (en) * 2003-03-05 2005-02-17 Tilia International, Inc. Method for manufacturing liquid-trapping bag for use in vacuum packaging
US20070063374A1 (en) * 2004-11-08 2007-03-22 Nicholas Barakat System and method for making polyethylene terephthalate sheets and objects
US20120181715A1 (en) * 2004-11-08 2012-07-19 Nicholas Barakat Advanced control system and method for making polyethylene terephthalate sheets and objects
US8545205B2 (en) * 2004-11-08 2013-10-01 Chemlink Capital Ltd. System and method for making polyethylene terephthalate sheets and objects
US8986587B2 (en) 2004-11-08 2015-03-24 Chemlink Capital System and method for making polyethylene terephthalate sheets and objects
US9011737B2 (en) * 2004-11-08 2015-04-21 Chemlink Capital Ltd. Advanced control system and method for making polyethylene terephthalate sheets and objects
US20100282412A1 (en) * 2009-05-09 2010-11-11 Dohe Dieter Method of making a protective film

Also Published As

Publication number Publication date
EP0908295B1 (fr) 2003-01-02
DE69810414T2 (de) 2003-05-22
JPH11105105A (ja) 1999-04-20
ES2189063T3 (es) 2003-07-01
EP0908295A3 (fr) 2000-05-24
ATE230347T1 (de) 2003-01-15
DE69810414D1 (de) 2003-02-06
JP3683688B2 (ja) 2005-08-17
EP0908295A2 (fr) 1999-04-14

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